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RE: ARGH!!: broken wire +

Original poster: gary350@xxxxxxxxxxxxx
This is what I have done several times and it works fine.

Use some sand paper to remove the enamel coating on the very tip of the wire. Over lap the wire about 1/8" and sold them together. Make sure there is no sharp points on the wire or solder. Use a very small file to file down the solder right down to the surface of the wire if you can. Make a special effort to make sure the solder connection is smooth. Paint the solder with polyurethane varnish. Continue winding your secondary coil but leave a tiny space on both sides of the solder splice. Move 1 turn of the wire over about 1/16" from the close wound section. Leave a tiny space on each side of the splice. It will make a goofy looking place on your secondary but it will work fine.

Check out this pic of my 10" coil. The coil arced about half way up shorting out 3 turns of the secondary coil. I unwrapped about 7 turns of wire and solder spliced the wire back together. It works fine.


Gary Weaver

-----Original Message-----
>From: Tesla list <tesla@xxxxxxxxxx>
>Sent: Jan 12, 2007 5:10 PM
>To: tesla@xxxxxxxxxx
>Subject: RE: ARGH!!: broken wire
>Original poster: "Derek" <tesla@xxxxxxxxxxxxxxxxxxxxxxxx>
>"while winding a new secondary, the wire broke about 2/3 of the way up!!
>what's the best thing to do? if I join it is it best to have the end of the
>secondary closest to the join as the base (i.e. closest to the primary) or
>use that end as the top to put the toroid on (it will be about 1.5" above
>the end of the coil..), also what's the best way to join the wire?
>Ouch, I hate it when that happens...."
>Last time I broke a wire in the middle of a long wind, I (after a number of
>attempts) soldered a really neat lap joint and carried on winding. After the
>wind was completed I used about 5 coats of varnish over the joint, sanding
>each time to ensure there was not a "live lump " left at the join.
>I suspect it is best to leave the joint at the toroid end of the coil, as
>there is usually less electric field there then in close proximity to strike
>rails and primary coils.
>The coil is still in use and has been used to create arcs of 42" even though
>the coil is only 22" long.
>         Derek